Firebag Project - FieldComm Group Forums for FOUNDATION Fieldbus

Wes Meger
• Director Stonehaven
Quality Controls Ltd.
• E/I Supervisor for
Suncor Firebag
Stages 1 and 2.
• >26 years of oilfield
experience.
Firebag - Location
Firebag - Land Position
•
Land
• Area extent: 1180 km2
• Acquisition cost: $69 MM
•
Recoverable bitumen
• Independent estimate: 9.9 B
barrels
•
Firebag could support approx.
1,000,000 bpd for 27 years
Firebag - Land Position
Integration
Downhole - The SAGD Process
Interface and
o
t
s
Co
low
Heated
Oil
Flows
to
Well
Oil and
Condensate
are Drained
Continuously
es
ens
nd
Stea
mF
Top of Oil Sands Reservoir
Steam
Injection
Steam Flows to Interface
and Condenses
Heated
Oil
Flows
to
Well
Horizontal
Well Pair
Bottom of Oil Sands Reservoir
Heated Oil
Flows to Well
Why use Fieldbus ?
• Total Installed Cost Savings (TIC)
– Reduced wiring
– Smaller footprint
– Faster commissioning
• Total Lifecycle Cost Savings (TLC)
– Instrument diagnostics
– Preventative maintenance
• Suncor had no previous FOUNDATION fieldbus
experience
Validation Process
Interest in Fieldbus
Benefits of TIC
Benefits of TLC
Gather data on
Benefits
Investigate Risk
Y
Use FF on
Pilot
Successful
Vendor
FAT testing
Y
Successful
SAIT
Stress Test
Y
Test FF during Pilot Startup
Commissioning !
Training !
Operations !
Vendor Presentations
Other Users
Papers, etc.
N
N
N
N
Reject Fieldbus
&
Use Classic Instrument
FF Testing
Validates
Savings
& Risks
Y
Use Fieldbus
On
Firebag Phase 1
Commercial
EPC Cost Model Summary
Suncor Firebag Foundation Fieldbus vs. Conventional 4-20 ma
Design Basis 1200 devices with 280 control loops
Fieldbus
savings
Instrumentation
Cdn $
+480,000
Wiring
-116,831
Control
System
Terminations
Construction
Rework
Loop
Drawings/
Engineering
Total
FF
Savings
+4,240
-270,900
-27,090
-126,555
-57,136
A (+) number represents added costs and a (–) number represents a savings.
SAIT SIFT
•
Stress test the Host and FOUNDATION fieldbus
•
Provide hands-on experience with live system
•
SAIT - accredited training, lab, neutral testing site and resource for
other vendor equipment
•
Validate design-normal conditions
– # of devices, cable lengths, voltages, timing
– Test design guidelines for FF commercial application
•
Explore the limitations and failures – abnormal conditions
–
–
–
–
–
•
Devices with/without DD files
Connect and disconnect components
Excessive terminations, instruments, voltages
Cross segment communications and control
Remove host, terminator, short circuits, etc
Final grade – A-
Pilot Commissioning
• Pilot - unique approach
– Conventional - 3men, 48 hours, 48 devices
– Fieldbus
- 2 men, 24 hours, 109 devices
– Results – FF devices in 1/6 the time
• Troubleshooting wiring is very simple
• Firebag Phase 1 Estimate (conservative)
– .25 hr/trans. + .75 hr/valve = $57,750
What about SIFT testing ?
• Can not be done the “old way”
• Munger “MIMIC” simulation software that can interface
to host directly and will simulate Fieldbus I/O and devices
along with control-in-the-field.
• Suncor used this product for both Stage 1 and Stage 2 to
test configuration and graphics prior to system leaving for
field, > 95% debugged.
• MIMIC is being enhanced to include DeviceNet and
Profibus.
Stage 1 Commissioning - positives
•
1130 FF devices – 275 control valves
•
1320 Conventional signals – 150 AI, 45 AO
•
Late May to late August
•
10 person crew – 5.7 per day
–
–
–
–
–
•
Power down checks
Commission to system
Function check
Verify HMI indication and alarms
Ran post-installation valve signatures to identify installation errors
Commissioning is faster
– Field staff picked up FOUNDATION fieldbus easily with little training
– All staff want to work FOUNDATION fieldbus commissioning when choice
available
– E/I Techs needed to adapt way of thinking – go to console first
Stage 1 Commissioning - positives
• Generally acknowledged that 75% of all start-up
delays directly relate to instrumentation and
controls.
• Firebag Stage 1 E/I not only did not cause any
delays, but were easily on schedule throughout
commissioning.
• Faster start-up = earlier production = $.
Start-up Results
• Troubleshooting is much faster
– Many activities reduced from 90 min. to 10 min
• Operating plant needs “hot” work permit for entry
– Permit operator not available
– 20 people lined up for permit
– With FF most troubleshooting is successful from the console with
no permit required
• 50% of devices require checks with 70%+ (no problem
found)
– Operators are learning the plant.
– When they don’t understand what is happening they tend to doubt
the instruments.
Foundation Fieldbus
• Vortex meters
– Production pads are 3.5 km from the plant CCR – lower flow rates
were required during start-up – 40 meters could all be re-configured
and low flow cutoff removed from the CCR with no travel required
• Corriolis meter
– Ease of observing the health of instrumentation by observing the right
& left coil voltages and live zero value
• MOV
– Motor Operated Valves (MOV) on feedwater pumps and tanks have
analog values in addition to on/off – Operator can select desired valve
position for testing or abnormal operation
DeviceNet Network
32 C-H WPONI modules
Average Current
Status - Run
Faulted
Warning
Ready
CFNet
Output -
Thermal Capacity
Fault Codes Hdw Link Fault
No Device Power
Incomplete Sequence
Invalid Device Version
Voltage
Thermal O/L
Phase Loss
Phase Imbalance
Gnd I Sense Loss
Memory Fault
Run
Reset
10 A-B SMM modules
Fault Warning
Average Current
Max Winding Temp.
Thermal Capacity
Earth Leakage Current
Phase Imbalance
10 A-B DSA modules
Status
Output - Run
CFNet
DeviceNet
• Pump startups simplified
– Console has voltage/current and thermal capacity displays
– Pump loads adjusted by Operations to compensate for insufficient
head pressure
– Eliminate shutdowns, false starts and damage to motors
• Reduced Commissioning
– Variable Frequency Drives (VFD) – all live parameters can be set
from the console thus eliminating trip to MCC with laptop
– VFD company representative was impressed with capability of the
DeltaV Devicenet interface – all 360 parameters could be viewed
and altered from CCR
• Faster Troubleshooting
– Able to read and reset faults from console
– Able to read motor nameplate data entered into SMMs and VFDs
Stage 1 Commissioning / Start-up Negatives
• 8 – 10 electronics failures
• HI_Lim parameter on one type of vortex
• Less functionality in FF configuring
• No factory valve signatures on vendor packages
• Heat related issues with power conditioners,
breakers and motor monitoring equipment
• Failures on two multi-port connectors
Temperature Issues
DeviceNet Network
Mid-term Report Card
• TIC approximately equivalent.
• Different skills required for troubleshooting networks.
• Room for improvement on some vendor equipment.
• Take extra time (maybe even do HAZOP) on network
designs.
• Performance does not suffer using bus technologies.
• Seeing some additional TLC value with potential to add
much more.
Maintenance Strategy
Firebag Maintenance Strategy
Value Based Maintenance
Value Based Maintenance is the strategy to improve the reliability of
systems and equipment by managing the risks associated with each based
on safety and economics.
Value = Benefit derived – Cost of Implementation
The main objective is to identify the items that are potentially critical with
respect to EH&S and production and analyze them with Failure Mode and
Effect Analysis. Specific failures are targeted and solutions are applied,
thus lowering the consequence and or frequency.
Rating Criticality
FIREBAG PROCESS SCHEMATIC - COST OF SHUTTING DOWN
Oil/Water Separation
(Sour Diluent)
DILUENT
FROM OS
SALES TANK
120 C
57% OIL
10% WATER
33% DILUENT
TREATER
FWKO
INLET SURGE
VESSEL
180 C
1,000 kPa
69% WATER
31% OIL
$52.90/M3 OIL
$12,123/HR
PROD. GAS SEP.
188 C 750 kPa
SALES
TO OS
80 C
63.59% OIL
0.5% WATER
36% DILUENT
Water Treatment: Oil Removal & Softening
w/ Disposal & Source
PRODUCED
WATER TANK
INDUCED STATIC
FLOTATION UNIT
2,000 PPM
OIL (MAX)
85 C
SKIM TANK
200 PPM
OIL
20 PPM
OIL
PRODUCED GAS TO OTSG
1 PPM
OIL
MAKEUP
WATER
FROM
OS
OIL REMOVAL
FILTERS
DISPOSAL
WATER
Field Facilities
PAD
SEPARATOR
219 C
2,165 kPa
Steam Generation
STEAM
SEPARATOR
270 C
5,500 kPa
Q=95%
INJECTION
WELL
PRODUCTION
WELL
$52.90/M3 OIL
$6,061/HR/PAD
320 C
11,100 kPa
Q=80%
80 C
80 C
STEAM
GENERATORS
BOILER
FEEDWATER
TANK
180 C
13,000 kPa
RECOV /
DISPOSAL
WATER
$17.63/M3 STEAM
$3,031/GEN/HR
WEAK ACID
CATION
PACKAGE
(Removes
Hardness)
LIME
SOFTENER
FILTER
(Removes
Solids
Carry-over
from WLS)
WARM LIME
SOFTENER
(Precipitates
Hardness and
Removes
Silica)
WLS FILTER
FEED TANK
LIME TO
SLUDGE
CENTRIFUGES
$17.63/M3 WATER
$10,108/HR
Ca (OH)2
MgO
Failure Modes and Effects Analysis (FMEA)
PV-81114A
Equipment
Functions
Produced
Vapour Control
Functional
Failures
Failure
Mode 1
ROI
Valve cage plugged
Cause
Cause
Design
based
Solution1
Trending &
Cleaning
7.11
Solution2
Overhaul
10 Months
2.7
Solution3
Change out
Trim
2.6
Solution4
Run to Fail
0.0
Operational
Failure
Mode 2
Trim worn
Cause
Cause
Root
Cause
Failure
Mode 3
Packing worn
Cause
Cause
$ 12,708
Annualized Cost of
Failure Modes
Root
Cause
V=B-C
$ 2,592
Solution Costs
Preventative Maintenance
Preventative Maintenance is inherently inefficient;
• Must be scheduled to repair problems before they
occur, usually end up conservative.
• Labor and materials are utilized whether
necessary or not.
• Totally ineffective is scheduled too late.
Predictive Maintenance
• A plan to predict failures before they occur.
• Requires frequent monitoring, trending and
analysis of critical parameters.
• Predictive monitoring adds no value until
information is analyzed and action is taken.
• Should trigger Preventative Maintenance.
FIREBAG MAINTENANCE VISION
% VALVE WEAR
% Efficiency
REPLACE VALVE (HIGHEST COST)
REPAIR VALVE
ADJUST VALVE (LOWEST COST)
Process Upset
L
RMA
O
N
H
AY
H IG
DEC
/
R
W EA
MAL
NOR AY
W
EC
LO
R/D
A
E
W
PROACTIE ZONE
TIME >
Valve Failure
REACTIVE ZONE
Equipment Fault
Process Upset
Loss of Efficiency Range
Implemented
•
•
•
Have an “FF Alert” HMI graphic
Using “Bad_PV” parameter for automatic failover
Valve signature baselines
Travel Deviation
Cycle Counter
Valve Signature
Step Response
Dynamic Error Band
Drive Signal
Output Signal
etc...
Configuration
Status / Alerts
Diagnostics
Calculations
Electronics Failure
Sensor Failure
Process Condition
Configuration Warning
Plugged Impulse Lines
etc...
pH Electrode Aging
Glass Electrode Failure
Reference Electrode Failure
Reference Electrode Coating
Reference Electrode Poisoning
etc...
Electronics Failure
Sensor Failure
Process Condition
Configuration Warning
RTD Drift
RTD Life Estimation
etc...
Electronics Failure
Sensor Failure
Reverse Flow
Empty Pipe
Calibration Error
Process Condition
Configuration Warning
etc...
Turnaround
• Valve signatures resulted in only 8 of
possible 32 valves being pulled and serviced.
• Had time to do signatures on all critical 1
valves, identified 1 that required immediate
attention.
• Able to easily complete all necessary tasks
and respond to “emergency” work
Good and Not Good
•
BadPV
–
–
–
•
use to do auto switchover to the back-up device
ring in when doing downloads to segment
should have time delays on alarms and shutdowns.
Alarm_Active
–
–
triggered by PV crossing *_LIM whether enabled or
not
Use CU_ALM instead.
Future
• Interfacing with CMMS (SAP) – FF alerts trigger
workorders
• Monitor valve signatures on critical 1 and 2 loops
• Advanced control schemes – fuzzy logic and multipredictive control
• Calibrate less frequently based on Audit trail
Stage 2
• New EPC, new staff.
• Different philosophy going into project.
– Reluctance to learn and embrace new technologies.
– Focus on cost and schedule.
• Less influence from field personnel.
• Result was failure to move forward with Fieldbus
utilization.
Summary
• Suncor Firebag Operations (field and
management) still very much committed to
realizing benefits of fieldbus technologies.
• Resources allocated for planning and
implementation, and to set standards for future
phases.
• Working with Vendor to piggy-back on other enduser experiences.
Questions?